Intermediate shaft rebuild question
 

Hi,

It appears that the teeth on my intermediate shaft are too worn to be put back in newly rebuilt engine. If I replace the gear, is that something that I can do myself with a press and gear puller?

Walt at CE says that it is important to measure the run out when you replace them, but I feel like the machining cost are never going to end...

So send the shaft and get over it?

Are you talking about the aluminum gear or the sprockets? Either one can be replaced and I don't think there is a run-out issue involved unless you have a bent shaft. You can check it by rotating the crank and intermediate gear in the case half before you close up the case. The sprockets are pressed on. I took mine to the local Napa auto parts to have it pressed apart. Then I put it back on by heating the sprocket and tapping it on with a pipe.

-Andy

If the engine builder is telling you it should be done, then you probably should. I'm a fairly new owner and have read that some people have issues with the intermediate shaft, so if the run-out check is a part of making sure it's right so that you don't have to tear your engine down earlier than expected, then why not do it??

I am not sure how Walt is doing the run-out check. The most accurate way is to do it in v-blocks. If you do it in the case you'll get pretty close but not as accurate due to clearances. A run-out check involves putting the shaft on a surface where you can spin the shaft and keep it concentric (center line of the shaft not moving) and putting a dial indicator on one or more surfaces. Walt might want to check the surface where the gear(s) are installed too to make sure they are not distorted. If you do find excess run-out, then yes, the repair means machine work. But from your post, it sounds like he only wants to check and confirm it is good.

PS...

Here's a pic of a set of dial indicators (A&C) and v-blocks (B).

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